General description and facilities
Taken from - ENGINEERING INSTRUCTIONS, TOOLS & TRANSPORT, VEHICLES, N 3021 (Issue 1, 16.8.66)
Box Builder's Vehicle
Until recently, Areas were equipped with rather inadequate vehicles for Box Building parties. These vehicles were not purpose-built and offered poor accommodation for sand, ballast and tools. A vehicle has been designed to remove these failings, to take advantage of the power tools now available and provide better crew accommodation, which should lead to more efficient operations on jointing chamber construction and maintenance.
The vehicle has a two seat cab, behind which is an enclosed compartment for tools and mechanical aids, and has a translucent roof to give maximum light. All the large tools provided are electrically driven, the power being supplied by a propane driven 110V generator. Propane fuel is not so inflammable as petrol so that the generator can be run in this enclosed compartment by using an exhaust extension. The major tools in the vehicle kit are a road breaker, hammer drill, water pump, concrete mixer (carried on rear platform) concrete vibrator, flood lamps, together with all necessary hand tools.
Below the enclosed tool compartment on both sides of the vehicle are compartments to accommodate other items, such as red lamps, paraffin cans, propane cylinders, cones reflecting and bags of cement. Clean water is an essential requirement for cement mixing and a 30 gallon tank is provided at the rear of the tool compartment.
The rear platform - which has drop sides for easy access - carries storage bins for sand and ballast, skips for the carriage and disposal of spoil, cement mixer, frames and covers, shuttering, etc.
For handling heavy items such as frames and covers of approximately 5.5 cwt., skips full of spoil approximately 10 cwt., an hydraulic powered crane is provided. This has a three section folding jib of one ton maximum load, and can be controlled from both sides of the vehicle. Stabilising jacks are provided either side of the crane mounting to steady the vehicle when the crane is in use.
The colour of the vehicle is Traffic Yellow. This is a safety measure, as in course of its work, the vehicle spends much of its time parked at the roadside, or in the carriageway and in dull weather or against dark backgrounds, the bright colour makes the vehicle as conspicuous as possible to other road users.
The new Box Building vehicle offers great advances in tool, material, and crew accommodation over the stores carrying vehicle previously used for these jobs. This together with the mechanical aid facilities should lead to more efficient operation of Box Building parties. Some 180 of these vehicles are being obtained most of which have by now been delivered to Telephone Areas.
PO ENGINEERING INSTRUCTIONS
Box Building Vehicle Type 1
2 General Description
3 Forward Compartment
The 2KW generator (Electric, Orange No. 2) fits underneath the bottom shelf close to the doorway. It is run on propane fuel and may be operated inside the compartment using the extension silencer, the power leads being extended to the electrically operated tools as required. The road breaker box is secured to the rails on the rear wall.
In order to keep the cement dry and to prevent cement dust from fouling the interior of the compartment, the cement locker (fig.4) has separate access doors on the off side and there is no connection between the locker and the interior of the compartment.
6. Water Tank
Drinking water should be carried separately in Bottles, Polythene, No. 2.
In cold weather the tank should be drained each night and on no account should any sort of anti-freeze be put into it. The purpose of the tank is to carry clean water for mixing concrete and mortar. The tank should be filled at the TEC (before commencing each days work) using a hose pipe attached to the water supply.
7. Rear Platform
A folding step is fitted to the tail board. The whole of the platform is covered with aluminium tread plate.
The base of the crane is extended to two stabiliser legs each of which consists of a cylinder with a manually operated piston. Oil is allowed to flow by gravity from the reservoir in the base of the crane via the control valve at the top of the cylinder into the cylinder. When the foot of the piston touches the ground, shutting the valve forms a hydraulically locked support leg. The leg is retracted by opening the valve, raising the leg manually to its full extent by means of the handle, and then closing the valve.
The working pressure of the hydraulic system is 1990 psi. The oil pump is driven from a side power take off on the gearbox and is engaged by means of a lever adjacent to the gear lever (Fig 8). A pilot light on the instrument panel indicates when the PTO is engaged (Fig. 9).
As first issued the crane was et to lift 1 ton at a radius of 5 feet, but this may be increased to 30 cwt at 5 feet (see para. 12.1).
9. Crane lifting capacity
When modified to the MT Works specification, quoted in Paragraph 12.1 the lift at the full extension of 11' 6" is 12.75 cwt. At a radius if 10' the lift is 15 cwt, at 7' radius 21 cwt and at 5' radius 30 cwt.
10. Lifting tackle
The Three Skips Stacking can be used for sand and ballast to a total quantity of 18 cwts. When empty the skips may be stacked to give more room on the rear platform. By using the skips solely for ballast and sand these materials are kept clean enabling mortar and concrete of good quality to be produced.
The two Skips Tipping are for the conveyance of spoil from site. Each holds 10 cwt of spoil. When loaded they should be positioned towards the front of the platform. They may be placed one on top of the other when empty.
11. Operation of the crane
11.1.1 Ensure that the handbrake is firmly on and that the vehicle is safely parked.
11.1.2 On arrival at the site use the rotating amber beacons until all warning signs, cones, etc, have been positioned. The beacons should then be switched off. If, however, it is considered that the situation requires the continuous use of flashing beacons those fixed to the vehicle may be used for short periods by running the engine to avoid discharging the battery. For all other continuous duty Beacons Electric Green numbers 1 or 2 should be employed together with the required battery and/or generator.
11.1.3 The stabiliser legs must be lowered and locked to prevent movement of the chassis under transverse load conditions. On soft ground stout boards should be placed under the stabiliser feet to spread the load.
11.1.4 The operator must make sure that there is no danger of fouling overhead power or telephone lines, street lighting or any other obstruction and also that the crane will not be operated so as to extend beyond the guarded working area where it might constitute a hazard to the public.
11.2 After the crane has been used and stowed in the normal
carrying position, operators
must ensure that:-
11.2.2 The PTO is disengaged before driving away.
11.3.1 The booms are raised from the folded and stored position by moving the top control lever towards the rear of the vehicle. Should this control move towards the front of the vehicle to raise the booms then a modification is required (see para. 12.2).
The booms should be raised to approximately 30 degrees above the horizontal as indicated by the small triangular hinged plate, situated on top of the inner boom, just reaching the end of its travel.
11.3.2 Operate the bottom control lever to slew the booms so that they lie in line with the body.
11.3.3 Operate the central lever to raise the outer boom to its maximum extension.
11.3.4. Operate the top lever to lower the inner boom slowly until the outer boom passes the vertical position and falls forward under gravity.
11.3.5 Operate the central lever to lower the outer boom.
11.3.6 Extend the outer boom by removing the "B" clip from the retaining pin, pulling out the extension and refitting the retaining pin and "B" clip.
11.4 Stowing the crane
11.14.1 Retract the manual outer boom extension.
11.14.2 Slew the crane so that the booms lie in line with the vehicle.
11.14..3 Elevate the inner boom to approximately 300 above the horizontal.
11.14.4. Fully extend the outer boom.
11.4.6 Lower the outer boom until it rest on the top of the inner boom.
11.4.7 Slew the booms so that they lie vertically above the stowed position.
11.4.8 Lower the booms into the stowed position.
11.4.9 Retract the stabiliser legs.
11.4.10 Disengage the power
11.5 General notes on the operation of the crane
More than one control may be operated at a time as for instance during lowering and slewing.
It is not possible to overload the crane as safety valves are incorporated, but it is possible to pick up a load at a short radius and extend the radius to a point where the crane will not sustain the load.
In this case the safety valve operates and the load is automatically lowered at a fixed rate but out of the operator's control. The load may be brought under control again by reducing the radius before the load reaches the ground.
All staff should stand well clear of the load at all times. The load must never be passed over anyone's head.
When lifting a load from the forward end of the platform it may be necessary to use the inner hook first and then transfer to the outer hook, reversing this procedure when loads are to be placed well forward.
When lowering a load over the rear of the vehicle care should be taken to fold up the tailboard step, to lower the side board adjacent to the controls in use, and to remove the rear corner post on that side.
Maintenance instructions for lorry loader are given in L0025.
14. Testing and Inspection
For tests and inspection of the lifting tackle see Routine, Q3030 and Q3031.
15. Use of vehicle
16. Vehicle Tools
17. Fire Extinguisher and First Aid Box
18. Spare wheel
The load on the rear platform must not exceed 2.25 tons and should be placed as far forward as possible. This load is also limited by other tools and stores carried and the Total GMW of 7 tons must not be exceeded.
20. Towing capacity
Last revised: November 15, 2019